INFLUENCE OF WIRE-EDM CONDITIONS ON WIRE WEAR RATIO AND FORM ERROR IN MACHINING MAGNESIUM COMPOSITE

The aim of this work is to investigate the effect of pulse ON, pulse OFF time, current and feed rate on output process parameters tool wire wear ratio, surface roughness, parallelism and flatness in Wire-EDM of Magnesium (AZ91) reinforced with 5% graphene (15 microns) and 2.5% B4C (37 microns) composite which was prepared using vacuum die casting. A rectangular profile of size 20×10mm having a thickness of 13mm was cut on Wire-EDM with Molybdenum wire of diameter 0.18mm as tool-electrode. Experiments were conducted based on L9 orthogonal array. Effect of input parameters was individually analyzed on corresponding output parameters using taguchi method. Analysis of Variance (ANOVA) was done. Results shows pulseon time has a maximum contribution on surface roughness and wire wear. Straightness and flatness is highly influenced by current.